Foldable display structures

ABSTRACT

One embodiment provides a structure, comprising: a display; at least one structural component disposed over a portion of the display, wherein the at least on structural component comprises at least one amorphous alloy; and wherein a portion of the display is foldable.

RELATED APPLICATION

This application claims priority from U.S. Provisional Application Ser.No. 61/522,949, filed Aug. 12, 2012, which is hereby incorporated byreference in its entirety.

BACKGROUND

Foldable displays are recently developed displays that may be very thinand made of solid-state semiconductor devices. In pre-existing OrganicLight Emitting Diode (“OLED”) displays, the semiconductor device sectionis generally 100 to 500 nanometers thick and comprises at least onelayer of an organic material. The semiconductor device portion of thepre-existing displays is generally supported by a substrate which ismade of clear plastic, glass, or very thin metallic foil. The primaryfunction of the substrate is for manufacturing purposes (for depositionand application of the organic layers); otherwise, the substrate doesnot provide any structural benefit.

One advantage of OLEDs is their ability to be rolled or folded intocompact shapes which may be an advantage for portable electronicdevices, whether hand-held smartphones or large area wall-mountabledisplays. However, the OLEDs do not have structural stability andrigidity to maintain a flat shape, especially after multiple foldingand/or rolling. This inability to remain flat may adversely affect theiroptimal function with the increasing demand for high definition display.The common materials used for the substrate of pre-existing displaystructures, such as plastics, aluminum, and glass, may not provideenough strength, rigidity, and durability without increasing thebulkiness of the display structures, which in turn adversely impacts theflexibility of OLED display.

SUMMARY

In view of the foregoing, the Inventor has recognized and appreciatedthe advantages of providing improved structural support to OLEDs toprovide and enhance their flatness and durability while preserving theirflexibility and ability to be folded or rolled into compact shapes formultiple uses.

Accordingly, provided in one embodiment is a structure, comprising: adisplay; at least one structural component disposed over a portion ofthe display, wherein the at least one structural component comprises atleast one amorphous alloy; and wherein a portion of the display isfoldable.

Another embodiment provides a method of making a foldable displaystructure, the method comprising: assembling a display with at least onestructural component, wherein the at least one structural component ismade by a method comprising: heating a feedstock comprising an alloythat is at least substantially amorphous to a first temperature that isgreater than or equal to a glass transition temperature (Tg) of thealloy; forming the heated feedstock into a preform; and cooling thepreform to a second temperature lower than the Tg to form the at leastone structural component.

Another embodiment provides a foldable display, comprising: a displaycomprising at least one organic light emitting diode; and a plurality ofstructural components disposed over a portion of the display; whereinthe plurality of the structural components comprises at least one bulksolidifying amorphous alloy; and wherein the display remains at leastsubstantially flat after multiple folding.

It should be appreciated that all combinations of the foregoing conceptsand additional concepts discussed in greater detail below (provided suchconcepts are not mutually inconsistent) are contemplated as being partof the inventive subject matter disclosed herein. In particular, allcombinations of claimed subject matter appearing at the end of thisdisclosure are contemplated as being part of the inventive subjectmatter disclosed herein. It should also be appreciated that terminologyexplicitly employed herein that also may appear in any disclosureincorporated by reference should be accorded a meaning most consistentwith the particular concepts disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The skilled artisan will understand that the drawings primarily are forillustrative purposes and are not intended to limit the scope of theinventive subject matter described herein. The drawings are notnecessarily to scale; in some instances, various aspects of theinventive subject matter disclosed herein may be shown exaggerated orenlarged in the drawings to facilitate an understanding of differentfeatures. In the drawings, like reference characters generally refer tolike features (e.g., functionally similar and/or structurally similarelements).

FIG. 1 provides a schematic of a foldable display structure according toone exemplary embodiment.

FIG. 2 provides a schematic of a foldable display structure according toone exemplary embodiment.

FIGS. 3( a)-3(b) provide a schematic of a foldable display structure andthe display in folded and rolled configurations, respectively, accordingto one exemplary embodiment.

DETAILED DESCRIPTION

Following are more detailed descriptions of various concepts related to,and embodiments of, inventive metal-containing coating and methods ofmaking and using the coating. It should be appreciated that variousconcepts introduced above and discussed in greater detail below may beimplemented in any of numerous ways, as the disclosed concepts are notlimited to any particular manner of implementation. Examples of specificimplementations and applications are provided primarily for illustrativepurposes.

Amorphous Alloys

An alloy may refer to a solid solution of two or more metal elements(e.g., at least 2, 3, 4, 5, or more elements) or an intermetalliccompound (including at least one metal element and at least onenon-metal element). The term “element” herein may refer to an elementthat may be found in the Periodic Table. A metal may refer to any ofalkali metals, alkaline earth metals, transition metals, post-transitionmetals, lanthanides, actinides, and metalloids.

An amorphous alloy may refer to an alloy having an amorphous,non-crystalline atomic or microstructure. The amorphous structure mayrefer to a glassy structure with no observable long range order; in someinstances, an amorphous structure may exhibit some short range order.Thus, an amorphous alloy may sometimes be referred to as a “metallicglass.” An amorphous alloy may refer to an alloy that is at leastpartially amorphous, including at least substantially amorphous, such asentirely amorphous, depending on the context. In one embodiment, anamorphous alloy may be an alloy of which at least about 50% is anamorphous phase—e.g., at least about 60%, about 70%, about 80%, about90%, about 95%, about 99% or more. The percentage herein may refer tovolume percent or weight percent, depending on the context. The term“phase” herein may refer to a physically distinctive form of asubstance, such as microstructure. For example, a solid and a liquid aredifferent phases. Similarly, an amorphous phase is different from acrystalline phase.

Amorphous alloys may contain a variety of metal elements and/ornon-metal elements. In some embodiments, the amorphous alloys maycomprise zirconium, titanium, iron, copper, nickel, gold, platinum,palladium, aluminum, or combinations thereof. In some embodiments, theamorphous alloys may be zirconium-based, titanium-based, iron-based,copper-based, nickel-based, gold-based, platinum-based, palladium-based,or aluminum-based. The term “M-based” when referred to an alloy mayrefer to an alloy comprising at least about 30% of the M element—e.g.,about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, about95%, or more. The percentage herein may refer to volume percent orweight percent, depending on the context.

An amorphous alloy may be a bulk solidifying amorphous alloy. A bulksolidifying amorphous alloy, or bulk amorphous alloy, or bulk metallicglass (“BMG”), may refer to an amorphous alloy that has at least onedimension in the millimeter range, which is substantially thicker thanconventional amorphous alloys, which generally have a thickness of 0.02mm. In one embodiment, this dimension may refer to the smallestdimension. Depending on the geometry, the dimension may refer tothickness, height, length, width, radius, and the like. In someembodiments, this smallest dimension may be at least about 0.5 mm—e.g.,about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm,about 8 mm, about 10 mm, about 12 mm, or more. The magnitude of thelargest dimension is not limited and may be in the millimeter range,centimeter range, or even meter range.

An amorphous alloy, including a bulk amorphous alloy, described hereinmay have a critical cooling rate of about 500 K/sec or less, in contrastto that of 10⁵ K/sec or more for conventional amorphous alloys. The term“critical cooling rate” herein may refer to the cooling rate below whichan amorphous structure is not energetically favorable and thus is notlikely to form during a fabrication process. In some embodiments, thecritical cooling rate of the amorphous alloy described herein may be,for example, about 400 K/sec or less—e.g., about 300 K/sec or less,about 250 K/sec or less, about 200 K/sec or less. Some examples of bulksolidifying amorphous alloys may be found in U.S. Pat. Nos. 5,288,344;5,368,659; 5,618,359; and 5,735,975. In some embodiments wherein thedesired diameter (or width, thickness, etc., depending on the geometry)is small, a higher cooler rate, such as one used in the conventionalamorphous alloy fabrication process, may be used.

The amorphous alloy may have a variety of chemical compositions. In oneembodiment, the amorphous alloy is a Zr-based alloy, such as a Zr-Tibased alloy, such as (Zr, Ti)_(a)(Ni, Cu, Fe)_(b)(Be, Al, Si, B)_(c),where each of a, b, c, is independently a number representing atomic %and a is in the range of from 30 to 75, b is in the range of from 5 to60, and c is in the range of from 0 to 50. Other incidental, inevitableminute amounts of impurities may also be present. In some embodiments,these alloys may accommodate substantial amounts of other transitionmetals, such as Nb, Cr, V, Co. A “substantial amount” in one embodimentmay refer to about 5 atomic % or more—e.g., 10 atomic %, 20 atomic %, 30atomic %, or more.

In one embodiment, an amorphous alloy herein may have the chemicalformula (Zr, Ti)_(b)(Ni, Cu)_(b)(Be)_(c), where each of a, b, c, isindependently a number representing atomic % and a is in the range offrom 40 to 75, b is in the range of from 5 to 50, and c is in the rangeof from 5 to 50. Other incidental, inevitable minute amounts ofimpurities may also be present. In another embodiment, the alloy mayhave a composition (Zr, Ti)_(b)(Ni, Cu)_(b)(Be)_(c), where each of a, b,c, is independently a number representing atomic % and a is in the rangeof from 45 to 65, b is in the range of from 7.5 to 35, and c is in therange of from 10 to 37.5 in atomic percentages.

In another embodiment, the amorphous alloy described herein may have thechemical formula (Zr)_(a)(Nb, Ti)_(b)(Ni, Cu)_(c)(Al)_(d), where each ofa, b, c, d is independently a number representing atomic % and a is inthe range of from 45 to 65, b is in the range of from 0 to 10, c is inthe range of from 20 to 40, and d is in the range of from 7.5 to 15.Other incidental, inevitable minute amounts of impurities may also bepresent.

In some embodiments, the amorphous alloy may be a ferrous-metal basedalloy, such as a (Fe, Ni, Co) based compositions. Examples of suchcompositions are disclosed in U.S. Pat. No. 6,325,868 and inpublications (A. Inoue et. al., Appl. Phys. Lett., Volume 71, p 464(1997)), (Shen et. al., Mater. Trans., JIM, Volume 42, p 2136 (2001)),and Japanese patent application 2000126277 (Pub. #2001303218 A). Forexample, the alloy may be Fe₇₂Al₅Ga₂P₁₁C₆B₄, or Fe₇₂Al₇Zr₁₀Mo₅W₂B₁₅.

Amorphous alloys, including bulk solidifying amorphous alloys, may havehigh strength and high hardness. The strength may refer to tensile orcompressive strength, depending on the context. For example, Zr andTi-based amorphous alloys may have tensile yield strengths of about 250ksi or higher, hardness values of about 450 Vickers or higher, or both.In some embodiments, the tensile yield strength may be about 300 ksi orhigher—e.g., at least about 400 ksi, about 500 ksi, about 600 ksi, about800 ksi, or higher. In some embodiments, the hardness value may be atleast about 500 Vickers—e.g., at least about 550, about 600, about 700,about 800, about 900 Vickers, or higher.

In one embodiment, ferrous metal based amorphous alloys, including theferrous metal based bulk solidifying amorphous alloys, can have tensileyield strengths of about 500 ksi or higher and hardness values of about1000 Vickers or higher. In some embodiments, the tensile yield strengthmay be about 550 ksi or higher—e.g., at least about 600 ksi, about 700ksi, about 800 ksi, about 900 ksi, or higher. In some embodiments, thehardness value may be at least about 1000 Vickers—e.g., at least about1100 Vickers, about 1200 Vickers, about 1400 Vickers, about 1500Vickers, about 1600 Vickers, or higher.

As such, any of the aforedescribed amorphous alloys may have a desirablestrength-to-weight ratio. Furthermore, amorphous alloys, particularlythe Zr— or Ti-based alloys, may exhibit good corrosion resistance andenvironmental durability. The corrosion herein may refer to chemicalcorrosion, stress corrosion, or a combination thereof.

The amorphous alloys, including bulk amorphous alloys, described hereinmay have a high elastic strain limit of at least about 0.5%, includingat least about 1%, about 1.2%, about 1.5%, about 1.6%, about 1.8%, about2%, or more—this value is much higher than any other metal alloy knownto date.

In some embodiments, the amorphous alloys, including bulk amorphousalloys, may additionally include some crystalline materials, such ascrystalline alloys. The crystalline material may have the same ordifferent chemistry from the amorphous alloy. For example, in the casewherein the crystalline alloy and the amorphous alloy have the samechemical composition, they may differ from each other only with respectto the microstructure.

In some embodiments, crystalline precipitates in amorphous alloys mayhave an undesirable effect on the properties of amorphous alloys,especially on the toughness and strength of these alloys, and as such itis generally preferred to minimize the volume fraction of theseprecipitates. However, there may be cases in which ductile crystallinephases precipitate in-situ during the processing of amorphous alloys,which may be beneficial to the properties of amorphous alloys,especially to the toughness and ductility of the alloys. One exemplarycase is disclosed in C. C. Hays et. al, Physical Review Letters, Vol.84, p 2901, 2000. In at least one embodiment herein, the crystallineprecipitates may comprise a metal or an alloy, wherein the alloy mayhave a composition that is the same as the composition of the amorphousalloy or a composition that is different from the composition of theamorphous alloy. Such amorphous alloys comprising these beneficialcrystalline precipitates may be employed in at least one embodimentdescribed herein.

A particular advantage of bulk solidifying amorphous alloys is theirstability in the supercooled liquid region, defined as the viscousliquid regime above the glass transition temperature in one embodiment.The stability of this viscous liquid regime may be generally measuredwith ΔT, which in one embodiment herein refers to the difference betweenthe onset of crystallization temperature, Tx, and the onset of glasstransition temperature, Tg, as determined from standard DifferentialScanning calorimetry (“DSC”) measurements at conventional heating rates(e.g. 20° C./min). In some embodiments, the bulk solidifying amorphousalloys may have ΔT of at least about 30° C.—e.g., at least about 50° C.,about 60° C., about 70° C., about 80° C., about 90° C., or more.

Foldable Display Structure (FDS)

One aspect of the embodiments described herein provides a foldabledisplay structure (“FDS”) comprising amorphous alloys, and methods ofmaking near-net shape foldable display structures from amorphous alloys.Due at least in part to the amorphous alloys, the FDS described hereinmay have characteristics that are both enabling and much improved overpre-existing display structures. The surprising advantages of foldabledisplay structures comprising amorphous alloys, particularly bulksolidifying amorphous alloys, will be described in various embodimentsbelow.

One embodiment provides FDS comprising amorphous alloys, the amorphousalloys providing form and shape durability combined with highflexibility, high resistance to chemical and environmental effects, andlow-cost near-net shape fabrication for intricate design and shapes.Another embodiment provides a method of making foldable displaystructures from such amorphous alloys in near-net shape. The amorphousalloys may be bulk solidifying amorphous alloys.

Provided in one embodiment is a structure, the structure containing adisplay, and at least one structural component disposed over a portionof the display. The display may contain at least one organic material,including an OLED. In one embodiment, the display need not contain anorganic material. In general, any flexible display material may be used.The display, or a portion thereof, may be foldable. In some embodiments,the entire structure is foldable. In one embodiment, the structure maybe, or may comprise, a foldable display and, optionally, structuralcomponents. In one embodiment the structure comprises a display and atleast one structural component.

The at least one structural component may contain at least one amorphousalloy. In one embodiment, the at least one structural component consistsessentially of an amorphous alloy. In another embodiment, the at leastone structural component consists of an amorphous alloy. The amorphousalloy may be any of the aforedescribed amorphous alloys, with any of theaforedescribed properties. In one embodiment, the amorphous alloy may bea bulk solidifying amorphous alloy.

The combination of high strength and high strength-to-weight ratio ofthe bulk solidifying amorphous alloys in one embodiment maysignificantly reduce the overall weight and bulkiness of foldabledisplay structures, thereby allowing for the reduction of the thicknessof these display structures while maintaining structural integrity andhigh flexibility. Furthermore, as described above, amorphous alloys,including bulk solidifying amorphous alloys, have high elastic strainlimits. This property is important for the use and application forfoldable display structures; specifically, a high elastic strain limitmay allow the display structure to be thin and highly flexible.Additionally, a high elastic strain limit also may allow the foldabledisplay structures described herein to sustain loading and/or flexingwithout permanent deformation or destruction and enable them to fold(and roll) into compact shapes for multiple use and opening and closure.The term “folding” herein may include “rolling” to refer to compacting amaterial. Due at least in part to the high elasticity, the foldabledisplay described herein after multiple folding and unfolding of thestructural component, may remain at least substantially flat, such ascompletely flat. In one embodiment, the foldable display may remain atleast substantially at the same level of flatness after multiple foldingand unfolding as before it was folded for the first time.

In addition, due at least in part to the amorphous alloy, the foldabledisplay structures described herein may exhibit resistance to corrosion(e.g., chemical corrosion, stress corrosion, etc.) and high inertness.The high corrosion resistance and inertness of the amorphous alloy inthe structural component may be useful for preventing foldable displaystructures from getting decayed due the environmental effects. Finally,the aforedescribed properties, in combination with the high strength,high hardness, high elasticity and corrosion resistance properties, mayprovide a foldable display structure that is durable and resistant towear and scratch during normal use.

The foldable display structures, including the display and thestructural component(s), described herein may have any geometry,including size or shape. The structure may have a symmetrical shape oran asymmetrical shape. In a plane view, the foldable display structuresmay be a square, rectangle, circle, elliptical, a polygon, or anirregular shape. In contrast to a frame or a housing, the structuralcomponent in many embodiments described herein does not cover an entiresurface of the display. The structural component(s) may also have avariety of geometries, depending at least in part on the geometry of thefoldable display. For example, the structural component may comprisewires, strips, fibers, ribbons, or combinations thereof. These wires,strips, fibers, ribbons, etc., may be disposed over (or directly on) thedisplay in parallel to each other (or almost parallel to each other) orthey may intersect one another to form a mesh. In one embodiment, theportion of the display that is foldable corresponds to the portion ofthe display over (or directly on) which the at least one structuralcomponent is disposed. The structural component may be joined to thedisplay by any technique. In one embodiment, the structural component isjoined to the display by a polymer, such as an epoxy glue or any othermaterial that may bond the structural component to the display.

The display structure described herein may have multiple layers. In oneembodiment, the structural component comprising an amorphous alloy maybe disposed over a substrate layer, which in turn may be disposed overthe display. The structural component may be sandwiched between thedisplay and the substrate or may be over (or directly on) the substratethat is over (or directly on) the display.

The structural components may have any suitable dimensions, depending onthe application. FIG. 1 shows a schematic of an exemplary foldabledisplay structure comprising a display 101 and a structural componentcomprising a series of horizontally aligned strips 102 comprising anamorphous alloy (e.g., bulk solidifying amorphous alloy). The strips mayhave a thickness of between about 0.1 mm and 2.0 mm—e.g., between about0.15 mm and about 1.5 mm, between about 0.2 mm and about 1.0 mm, betweenabout 0.4 mm and about 0.8 mm, between about 0.5 mm and about 0.6 mm.Other ranges are also possible. The strips may have a width of betweenabout 0.5 and about 20.0 mm—e.g. between about 1.0 mm and about 15 mm,between about 2.0 mm and about 10 mm, between about 4.0 mm and about 8.0mm, between about 5.0 mm and about 6.0 mm. Other ranges are alsopossible. The length of the strips may vary, depending at least in parton the geometry of the display over (or directly on) which thestructural component is disposed. The strips may be extended to the edgeof the display or extended further outward of the edge of the display.In this embodiment, the display may be folded (including being rolled)in a segmented manner, with the strips providing certain rigidity alongthe display. In a preferred embodiment the strips are bonded to OLEDdisplay with various joining methods such as using epoxy glue.

FIG. 2 shows a schematic of an exemplary foldable display structurecomprising a display 101 and a structural component comprising a mesh ofhorizontally and longitudinally aligned fibers 103 comprising anamorphous alloy (e.g., bulk solidifying amorphous alloy). The fibers mayhave a diameter of between about 0.01 mm and 2.0 mm—e.g., between about0.02 mm and about 1.5 mm, between about 0.03 mm and about 1.0 mm,between about 0.05 mm and about 0.5 mm, between about 0.1 mm and about0.4 mm, between about 0.2 mm and about 0.3 mm. Other ranges are alsopossible. The mesh network may be extended to the edge of the display ormay be extended further outward of the edge of the display. In thisembodiment, the display can be folded in a continuous manner, whereinthe fiber mesh provides flexibility for rolling and rigidity andflatness upon opening of the display. In one embodiment the fiber meshis bonded to the display with various joining methods such as usingepoxy glue.

FIG. 3( a) shows a schematic of an exemplary foldable display structurecomprising a display 101 and a structural component comprising a set oflongitudinally aligned ribbons 104 comprising an amorphous alloy (e.g.,bulk solidifying amorphous alloy). The ribbons may have a thickness ofbetween about 0.01 mm and 2.0 mm—e.g., between about 0.02 mm and about1.5 mm, between about 0.03 mm and about 1.0 mm, between about 0.05 mmand about 0.5 mm, between about 0.1 mm and about 0.4 mm, between about0.2 mm and about 0.3 mm. The ribbons may have a width of between about0.5 and about 20.0 mm—e.g. between about 1.0 mm and about 15 mm, betweenabout 2.0 mm and about 10 mm, between about 4.0 mm and about 8.0 mm,between about 5.0 mm and about 6.0 mm. The ribbons may be extended tothe edge of the display or may be extended further outward of the edgeof the display. In this embodiment, the display may be folded in acontinuous manner, wherein the ribbons may provide flexibility forrolling and rigidity and flatness upon opening of the display. In oneembodiment the ribbon mesh is bonded to the display with various joiningmethods such as using epoxy glue.

In some embodiments described herein, the terms “ribbons” and “fibers”refer to highly flexible components, each of which may be folded (asshown in 201 in FIG. 3( b)) into a diameter in the range of about 10 mmto about 100 mm (e.g., about 20 mm to about 80 mm, about 40 mm to about60 mm), whereas the terms “strips” and “wires” refer to relatively rigidcomponents, each of which can be folded into a diameter larger than 30mm (e.g., larger than 40 mm, 50 mm, 60 mm, or larger).

Due at least in part to the desired properties as described above, theFDS described herein may be employed as a component of a variety ofdevices, including an electronic device. An electronic device herein mayrefer to a mobile phone, smart phone, PDA, computer (e.g., laptop,desktop, tablet computer, etc.), television, and various wall-mountabledisplays. A device may contain a plurality of the FDSs described herein.In one embodiment, multiple FDSs may be joined together to form onelarge display. For example, FDS of a small size (e.g., smaller than apre-existing personal reader or tablet computer) may function assecondary displays off one device (e.g., smart phone). In one embodimentwherein the FDSs are a part of a smart phone, one FDS may be used toperform navigation function while another to read email, and at the sametime the smart phone may be used for talking—this may be done with onedata plan as well. In another embodiment, at home or in office, one“connected” device may be used to drive multiple FDSs, some as TVs, someas computers, and some as communication devices simultaneously,sequentially, or both. In at least one embodiment, the displaystructures described herein are more desirable due to their extremelight weight, flexibility and being less prone to breakage, incomparison to the pre-existing glass-based displays such as LCD (LiquidCrystal Displays).

Method of Making

Another aspect of the embodiments described herein provides a method ofmaking a foldable display structure, such as one in near-net shape form,which display structure comprises a display comprising an organicmaterial and at least one structural component comprising at least oneamorphous alloy. The display and the structural component may be any ofthose described above.

One embodiment provides a method of making a foldable display structure,the method comprising: providing a feedstock of amorphous alloy beingsubstantially amorphous and having an elastic strain limit of about 1.5%or greater and a ΔT of 30° C. or greater; heating the feedstock toaround the glass transition temperature; shaping the heated feedstockinto the desired near-net shape of foldable display structure; andcooling the formed part to temperatures far below the glass transitiontemperature. As described above, ΔT refers to the difference between theonset of crystallization temperature, Tx, and the onset of glasstransition temperature, Tg, In one embodiment, a temperature aroundglass transition refers to a temperature that can be below glasstransition, at or around glass transition, and above glass transitiontemperature, but always at a temperature below the crystallizationtemperature Tx. The cooling step may be carried out at rates similar tothe heating rates at the heating step. Alternatively, it may be carriedout at rates greater than the heating rates at the heating step. Thecooling step may be also achieved while the forming and shaping aremaintained.

One embodiment provides a method of making a foldable display structure,the method comprising: providing a homogeneous alloy ingot (notnecessarily fully or partially amorphous); heating the feedstock to acasting temperature above the melting temperatures; introducing themolten alloy into the die cavity having the near-net shape of foldabledisplay structures and quenching the molten alloy to temperatures belowglass transition.

One embodiment provides a method of making a foldable display structure,the method comprising: assembling a display with at least one structuralcomponent. The assembling may involve disposing and/or joining the atleast one structural component over a portion of the display. Asdescribed above, the joining may involve gluing together (e.g. withepoxy glue) the display and the at least one structural component. Oneadvantage of the methods described herein is that the assembling of thecomponents of the foldable display structure may involve no (or minimal)use of fasteners.

In one embodiment wherein the display structures provided herein have asubstrate and a display, the structural component may be disposed over(or directly on) the substrate during production of the substrate. Thesubstrate may be contain any material, including those used inpre-existing displays, such as plastics, glass, etc. Because anamorphous alloy (of the structural component) may withstand highertemperatures than most plastics and synthetic substrate material,synthetic material may be poured over the structural component to forman intimate bond. The bond may be chemical, physical, or both. Anintimate bond may refer to a bond that has very little observable gapbetween the bonded components, and in some instances, as a result, thatthe components may not separate easily. Alternatively, structuralcomponent(s) may be provided between two sticky substrate materials sothat all of these may be bonded.

The at least one structural component may be made by a methodcomprising: heating a feedstock comprising an alloy that is at leastsubstantially amorphous to a first temperature that is greater than orequal to a glass transition temperature (Tg) of the alloy; forming theheated feedstock into a preform; and cooling the preform to a secondtemperature lower than the Tg to form the at least one structuralcomponent.

The feedstock may comprise an alloy that is at least partially, such asat least substantially, such as completely, amorphous. The method mayfurther include a method of making an alloy feedstock. The method ofmaking an alloy feedstock may include: heating at least one ingotcomprising an alloy that is at least partially not amorphous to a thirdtemperature that is higher than or equal to a melting temperature (Tm)of the alloy; and cooling the heated ingot at a rate that is sufficientto form the feedstock comprising an alloy that is at least substantiallyamorphous. The ingot may comprise a mixture of elements to be alloyed toform the feedstock. The ingot may be homogeneous (although it need notbe) with respect to the chemical composition of the elements of thealloy mixture, but may not be of an amorphous phase. The cooling rateduring the making of the feedstock may be fast enough to bypass thecrystallization formation region in the Time-Temperature-Transformation(TTT) diagram to avoid formation of a crystalline phase, thereby to forma feedstock that is at least partially amorphous.

In one embodiment, during the process of making a foldable displaystructure, the heated feedstock is formed into a preform before thepreform is cooled to form the final structural component of the displaystructure. The forming may include, for example, shaping the preforminto a desired shape. This process may involve any techniques known inthe art. For example, this may involve die casting, involvingintroducing the feedstock into a cavity of a die to form a preform. Insome embodiments, the forming may involve shaping the feedstock into thepreform with pressure. The pressure may be mechanical pressure, forexample by hand, tool, or air pressure. The preform may be near-netshape of the structural component. In other words, no (or minimal)additional processing would be needed to shape the preform into thedesired shape of the structural component. In some embodiments, certainpost-processing, such as certain surface treatments, may be employed.For example, surface treatment may be employed to remove oxides on thesurface. Chemical etching (with or without masks), as well as lightbuffing and polishing operations, may also be employed to improve thesurface finish.

The near-net shape of the structural component of the display structuresduring the processes described herein is one distinguishing featurecompared to the pre-existing process. Specifically, the preferredmaterial of the pre-existing process, which employs shape-memory Ti—Nialloys and/or spring steels, may only be produced in very limited shapesand forms, such as wires and flat strips because of the difficultythereof to produce near-net shaped products. By contrast, the near-netshape forming ability of amorphous alloys, particularly bulk solidifyingamorphous alloy, of the processes described herein allow fabrication ofintricate foldable display structures with high precision and reducedprocessing steps. Additionally, this may also allow minimal use ofbending and welding, which can reduce the structural performance andincrease manufacturing costs and aesthetic defects. In one embodiment,producing foldable display structures in near-net shape form may reducesignificantly the manufacturing costs while still forming foldabledisplay structures with intricate features, such as precision curves,and a high surface finish on aesthetically sensitive areas. Also, not tobe bound by any particular theory, but (bulk solidifying) amorphousalloys retain their fluidity from above the melting temperature down tothe glass transition temperature due to the lack of a first order phasetransition. This is distinguishable from conventional crystalline metalsand alloys, or even certain amorphous alloys in some instances. Becauseamorphous alloys retain their fluidity, they do not accumulatesignificant stress from their casting temperatures down to below theglass transition temperature. Thus, dimensional distortions from thermalstress gradients can be minimized.

Exemplary Embodiments

The following exemplary embodiments are provided in the Summary andClaims of the parent provisional application U.S. Ser. No. 61/522,949,filed Aug. 12, 2012.

In one embodiment, the foldable display structure comprises at least onepart made of bulk solidifying amorphous alloy.

In another embodiment, the foldable display structure compriseslongitudinally aligned ribbons or fibers substantially made of bulksolidifying amorphous alloy and attached to the back (substrate side) ofOLED display.

In another embodiment, the foldable display structure compriseshorizontally aligned ribbons or fibers substantially made of bulksolidifying amorphous alloy and attached to the back of OLED display.

In still another embodiment, the foldable display structure comprises amesh of ribbons or fibers substantially made of bulk solidifyingamorphous alloy and attached to the back of OLED display.

In still another embodiment, the foldable display structure comprises aset of ribbons or fibers substantially made of bulk solidifyingamorphous alloy and joined to the back of OLED display.

In still another embodiment, the foldable display structure comprisesdiagonally crossing and rigid strips or wires substantially made of bulksolidifying amorphous alloy and attached to the back of OLED display.

In one embodiment, the foldable display structure is at least partiallymade of a Zr—Ti base bulk solidifying amorphous alloy.

In another embodiment, the bulk solidifying amorphous alloy in thefoldable display structure is Be free.

In another embodiment, the foldable display structure is at leastpartially made of a Zr/Ti base bulk solidifying amorphous alloy within-situ ductile crystalline precipitates.

In another embodiment, a molten piece of bulk solidifying amorphousalloy is cast into a near-net shape manufactured foldable displayStructure.

In another embodiment, a stock feed of bulk solidifying amorphous alloyis molded into a near-net shape manufactured foldable display Structure.

In another embodiment, at least part of a near-net shape manufacturedfoldable display structure is formed by casting or molding the bulksolidifying amorphous alloy.

In another embodiment, the near-net shape manufactured foldable displaystructure is a near-net shape molding component.

In another embodiment, the near-net shape manufactured Foldable displaystructure is a near-net shape cast component.

One embodiment provides a method of fabricating a near-net shapemanufactured foldable display structure comprising the following steps:providing a feedstock of molten alloy at above Tm; introducing themolten alloy to a die cavity having the near-net shape of foldabledisplay Structure; quenching and taking the part out of the die cavity;and final finishing.

Another embodiment provides a method of fabricating a near-net shapemanufactured foldable display structure comprising the following steps:providing a feedstock of alloy that is at least partially amorphous;heating the feedstock to above Tg but below Tx, shaping the heatedfeedstock into desired near-net shape foldable display structure;cooling; and final finishing.

Another embodiment provides a foldable display structure comprising bulksolidifying amorphous alloys.

Another embodiment provides a method of making foldable displaystructure in a near-net shape form comprising bulk solidifying amorphousalloys.

Another embodiment provides a foldable display structure having astructure substantially made of bulk solidifying amorphous alloys,wherein the structural components are secured without the use offasteners.

Conclusion

All literature and similar material cited in this application,including, but not limited to, patents, patent applications, articles,books, treatises, and web pages, regardless of the format of suchliterature and similar materials, are expressly incorporated byreference in their entirety. In the event that one or more of theincorporated literature and similar materials differs from orcontradicts this application, including but not limited to definedterms, term usage, described techniques, or the like, this applicationcontrols.

While the present teachings have been described in conjunction withvarious embodiments and examples, it is not intended that the presentteachings be limited to such embodiments or examples. On the contrary,the present teachings encompass various alternatives, modifications, andequivalents, as will be appreciated by those of skill in the art.

While various inventive embodiments have been described and illustratedherein, those of ordinary skill in the art will readily envision avariety of other means and/or structures for performing the functionand/or obtaining the results and/or one or more of the advantagesdescribed herein, and each of such variations and/or modifications isdeemed to be within the scope of the inventive embodiments describedherein. More generally, those skilled in the art will readily appreciatethat all parameters, dimensions, materials, and configurations describedherein are meant to be exemplary and that the actual parameters,dimensions, materials, and/or configurations will depend upon thespecific application or applications for which the inventive teachingsis/are used. Those skilled in the art will recognize, or be able toascertain using no more than routine experimentation, many equivalentsto the specific inventive embodiments described herein. It is,therefore, to be understood that the foregoing embodiments are presentedby way of example only and that, within the scope of the appended claimsand equivalents thereto, inventive embodiments may be practicedotherwise than as specifically described and claimed. Inventiveembodiments of the present disclosure are directed to each individualfeature, system, article, material, kit, and/or method described herein.In addition, any combination of two or more such features, systems,articles, materials, kits, and/or methods, if such features, systems,articles, materials, kits, and/or methods are not mutually inconsistent,is included within the inventive scope of the present disclosure.

Also, the technology described herein may be embodied as a method, ofwhich at least one example has been provided. The acts performed as partof the method may be ordered in any suitable way. Accordingly,embodiments may be constructed in which acts are performed in an orderdifferent than illustrated, which may include performing some actssimultaneously, even though shown as sequential acts in illustrativeembodiments.

All definitions, as defined and used herein, should be understood tocontrol over dictionary definitions, definitions in documentsincorporated by reference, and/or ordinary meanings of the definedterms.

The indefinite articles “a” and “an,” as used herein in thespecification and in the claims, unless clearly indicated to thecontrary, should be understood to mean “at least one.”

The terms “substantially” and “about” used throughout this Specificationare used to describe and account for small fluctuations. For example,they can refer to less than or equal to ±5%, such as less than or equalto ±2%, such as less than or equal to ±1%, such as less than or equal to±0.5%, such as less than or equal to ±0.2%, such as less than or equalto ±0.1%, such as less than or equal to ±0.05%.

The phrase “and/or,” as used herein in the specification and in theclaims, should be understood to mean “either or both” of the elements soconjoined, i.e., elements that are conjunctively present in some casesand disjunctively present in other cases. Multiple elements listed with“and/or” should be construed in the same fashion, i.e., “one or more” ofthe elements so conjoined. Other elements may optionally be presentother than the elements specifically identified by the “and/or” clause,whether related or unrelated to those elements specifically identified.Thus, as a non-limiting example, a reference to “A and/or B”, when usedin conjunction with open-ended language such as “comprising” can refer,in one embodiment, to A only (optionally including elements other thanB); in another embodiment, to B only (optionally including elementsother than A); in yet another embodiment, to both A and B (optionallyincluding other elements); etc.

As used herein in the specification and in the claims, “or” should beunderstood to have the same meaning as “and/or” as defined above. Forexample, when separating items in a list, “or” or “and/or” shall beinterpreted as being inclusive, i.e., the inclusion of at least one, butalso including more than one, of a number or list of elements, and,optionally, additional unlisted items. Only terms clearly indicated tothe contrary, such as “only one of” or “exactly one of,” or, when usedin the claims, “consisting of,” will refer to the inclusion of exactlyone element of a number or list of elements. In general, the term “or”as used herein shall only be interpreted as indicating exclusivealternatives (i.e. “one or the other but not both”) when preceded byterms of exclusivity, such as “either,” “one of,” “only one of,” or“exactly one of” “Consisting essentially of,” when used in the claims,shall have its ordinary meaning as used in the field of patent law.

As used herein in the specification and in the claims, the phrase “atleast one,” in reference to a list of one or more elements, should beunderstood to mean at least one element selected from any one or more ofthe elements in the list of elements, but not necessarily including atleast one of each and every element specifically listed within the listof elements and not excluding any combinations of elements in the listof elements. This definition also allows that elements may optionally bepresent other than the elements specifically identified within the listof elements to which the phrase “at least one” refers, whether relatedor unrelated to those elements specifically identified. Thus, as anon-limiting example, “at least one of A and B” (or, equivalently, “atleast one of A or B,” or, equivalently “at least one of A and/or B”) canrefer, in one embodiment, to at least one, optionally including morethan one, A, with no B present (and optionally including elements otherthan B); in another embodiment, to at least one, optionally includingmore than one, B, with no A present (and optionally including elementsother than A); in yet another embodiment, to at least one, optionallyincluding more than one, A, and at least one, optionally including morethan one, B (and optionally including other elements); etc.

In the claims, as well as in the specification above, all transitionalphrases such as “comprising,” “including,” “carrying,” “having,”“containing,” “involving,” “holding,” “composed of,” and the like are tobe understood to be open-ended, i.e., to mean including but not limitedto. Only the transitional phrases “consisting of” and “consistingessentially of” shall be closed or semi-closed transitional phrases,respectively, as set forth in the United States Patent Office Manual ofPatent Examining Procedures, Section 2111.03.

The claims should not be read as limited to the described order orelements unless stated to that effect. It should be understood thatvarious changes in form and detail may be made by one of ordinary skillin the art without departing from the spirit and scope of the appendedclaims. All embodiments that come within the spirit and scope of thefollowing claims and equivalents thereto are claimed.

1. A structure, comprising: a display; at least one structural componentdisposed over a portion of the display, wherein the at least onestructural component comprises at least one amorphous alloy; and whereina portion of the display is foldable.
 2. The structure of claim 1,wherein the amorphous alloy is a bulk solidifying amorphous alloy. 3.The structure of claim 1, wherein the display comprises an organicmaterial.
 4. The structure of claim 1, wherein the at least onestructural component comprises wires, strips, fibers, ribbons, orcombinations thereof.
 5. The structure of claim 1, wherein the at leastone structural component comprises a mesh of wires, strips, fibers,ribbons, or combinations thereof
 6. The structure of claim 1, whereinthe at least one structural component comprises (i) fibers having adiameter of between about 0.05 mm and about 0.5 mm, or (ii) ribbonshaving a thickness of between about 0.05 mm and about 0.5 mm and a widthof about 2 mm and about 10 mm.
 7. The structure of claim 1, wherein theat least one structural component is not disposed over an entirety ofthe display.
 8. The structure of claim 1, wherein the at least oneamorphous alloy comprises a Zr-based, a Ti-based, a Zr—Ti-based, anFe-based, or combinations thereof, amorphous alloy.
 9. The structure ofclaim 1, wherein the portion of the display that is foldable correspondsto the portion of the display over which the at least one structuralcomponent is disposed and remains at least substantially flat aftermultiple folding.
 10. The structure of claim 1, wherein the structure isa part of an electronic device.
 11. A method of making a foldabledisplay structure, the method comprising: assembling a display with atleast one structural component, wherein the at least one structuralcomponent is made by a method comprising: heating a feedstock comprisingan alloy that is at least substantially amorphous to a first temperaturethat is greater than or equal to a glass transition temperature (Tg) ofthe alloy; forming the heated feedstock into a preform; and cooling thepreform to a second temperature lower than the Tg to form the at leastone structural component.
 12. The method of claim 11, further comprisingmaking the feedstock by a method comprising: heating at least one ingotcomprising an alloy that is at least partially not amorphous to a thirdtemperature that is higher than or equal to a melting temperature (Tm)of the alloy; and cooling the heated ingot at a rate that is sufficientto form the feedstock comprising an alloy that is at least substantiallyamorphous.
 13. The method claim 12, wherein the ingot comprises thealloy homogeneous with respect to a chemical composition thereof
 14. Themethod claim 11, wherein forming further comprises shaping the at leastone structural component with a pressure.
 15. The method of claim 11,wherein the preform has a near-net shape of the at least one structuralcomponent of the foldable display structure.
 16. The method of claim 11,wherein the assembling further comprises disposing the at least onestructural component over a portion of the display.
 17. The method ofclaim 11, wherein the assembling further comprises joining the at leastone structural component to the display using epoxy glue.
 18. The methodof claim 11, where the assembling further comprises securing the atleast one structural component over the display without using fasteners.19. The method of claim 11, further comprising post-processing of thefoldable display structure after the assembling.
 20. The method of claim11, further comprising repeatedly folding and unfolding the foldabledisplay structure, wherein the foldable display structure remains atleast substantially flat after the repeated folding and unfolding.
 21. Afoldable display, comprising: a display comprising at least one organiclight emitting diode; and a plurality of structural components disposedover a portion of the display; wherein the plurality of the structuralcomponents comprises at least one bulk solidifying amorphous alloy; andwherein the display remains at least substantially flat after multiplefolding.
 22. The foldable display of claim 21, wherein the plurality ofthe structural components has an elastic strain limit of at least 1.5%.23. The foldable display of claim 21, wherein the plurality of thestructural components has a ΔT of at least about 30° C.
 24. The foldabledisplay of claim 21, wherein the bulk solidifying amorphous alloy is atleast substantially free of Be.
 25. The foldable display of claim 21,wherein the bulk solidifying amorphous alloy further comprises aplurality of crystalline precipitates.